Apparatus for forming a wiring system

ABSTRACT

Method and apparatus for installing electrical wire or the like along a predetermined path on the surface of a base member by providing a groove in the surface of the base member along the predetermined path, simultaneously positioning in the groove guide means for laying said electrical wire and nozzle means for applying a material for maintaining the electrical wire within the groove, and then feeding electrical wire and said material to said guide means and nozzle means while moving the guide means and said nozzle means along said groove.

[ Feb. 1,1972

United States Patent Hawkins 1541 APPARATUS FOR FORMING A WIRING 3,212,115 10/1965 Crowell..............................156/295 x .156/332 x FOREIGN PATENTS OR APPLICATIONS 91,782 5/1930 Australia..........,....................

3,235,520 2/1966 Crowell.............................

SYSTEM [72] Inventor:

Paul Maddison Hawkins, Stillwater, Minn.

[73] Assignee: General Alarm Corporation, New York,

2 F] d: 3 1968 Primary Examiner--Carl D. Quarforth I 2] 1e June Assistant ExaminerE. E. Lehmann 121 Appl.No.: 733,854

Attorney-Ward, McElhannon, Brooks, & Fitzpatrick ABSTRACT Method and apparatus for installing electrical wire or the like [52] 1U.S.Cl...............................l56/433,1'18/410,156/390, 156/578 [51] Int. along a predetermined path on the Surface of a base member [58] Flew by providing a groove in the surface of the base member along the predetermined path, simultaneously positioning in the 118/234 410; 13 H groove guide means for laying said electrical wire and nozzle means for applying a material for maintaining the electrical [56] References cued wire within the groove, and then feeding electrical wire and UNITED STATES PATENTS said material to said guide means and nozzle means while moving the guide means and said nozzle means along said groove.

228/53 156/578 156/272 14 Claims, 7 Drawing Figures 2,054,506 9/1936 Leitsch........ 2,762,716 9/1956 MacKenzie 2,962,802 12/1960 Pierson..................................

P TENIEU FEB H972 3.639.193

SHEET 1 OF 2 PATENTEU FEB 1 I972 SHEET 2 [IF 2 BY WW WyW mf fi APPARATUS FOR FORMING A WIRING SYSTEM This invention relates to a method and apparatus for disposing an element of indefinite continuous length such as a wire or the like on a base member and, in its particular aspects, to a method and apparatus for disposing such an element within a longitudinally extending groove provided on the surface of a base member.

Those persons skilled in the art, especially those concerned with the installation of security and alarm systems, are aware of the constant and continuing efforts to improve the methods and apparatus for installing wiring systems in base members, such as, for example, walls, floors and other structural members. These artisans appreciate that, while numerous improvements have been made over the years, a relatively simple and economical method and apparatus for achieving the above objective have not been brought forward.

Thus, the present invention contemplates a novel method and apparatus of the class described which may be carried out and operated by persons of ordinary skill, and which are economical to use and make.

In accordance with one aspect of the present invention, there is contemplated a method for installing an element of indefinite continuous length such as electrical wire or the like along a predetermined path on the surface of a base member, such as a wall, floor or other structural member. First, a groove is provided in the surface of the base member along the mentioned predetermined path. Thereafter, guide means for laying the electrical wire within the groove and nozzle means for applying a material maintaining the wire within the groove are simultaneously positioned adjacent the groove. The nozzle means and the guide means are arranged so that the wire is first laid in position by the guide means and then covered with the material by the nozzle means. When so positioned, both the guide means and the nozzle means are moved parallel to the surface of the base member and above the groove while the wire being laid in the groove and the material are continuously fed to the guide means and the nozzle means, respectively, whereby the wire is disposed and secured within the groove placed in the base member.

In accordance with another aspect of the present invention, there is contemplated an apparatus for facilitating the fruition of the above method. This apparatus comprises a housing which is constructed to carry on a reel a length of electrical wire or the like, and which is arranged to be moved along the predetermined path. Guide means, projecting from the housing, are provided to receive the wire carried by the reel and to position same on a surface of the base member. In addition, a supply chamber is provided within the housing and is constructed to contain material for securing said wire to the surface of the base member. Also, nozzle means, communicating with said supply chamber, are arranged to project from the housing so as to apply said material over the wire positioned on the surface of the base member by the guide means whereby the wire is secured to the base member as the tool is moved along the predetermined path.

in accordance with still another aspect of the present invention, the supply chamber is constructed to contain a thermoplastic material and, in addition, heating means cooperating with the supply chamber are provided for heating the thermoplastic material to a pliable state. Switch means are provided in the housing for selectively actuating the mentioned heating means. Additionally, regulating means are connected to the supply chamber for regulating the passage of the mentioned pliable thermoplastic material to the nozzle means. Trigger means, connected to both the regulating means and the switch means, are also provided in the housing and are constructed and arranged to be moved so as to simultaneously actuate the switch means and the regulating means.

There have thus been outlined rather broadly the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures for carrying out the several aspects of the invention. It is important, therefore, that the claims be regarded as including such equivalent constructions as do not depart from the spirit and scope of the invention.

Specific embodiments of the invention have been chosen for purposes of illustration and description, and are shown in the accompanying drawings forming a part of the specification, wherein:

FIG. ii is a perspective view showing apparatus constructed in accordance with the present invention for disposing electrical wire on the surface of a base member;

FIG. 2 is an enlarged view, partially in section, of the apparatus illustrated in FIG. 1 and showing the structural detail of the supply chamber, nozzle means and guide means thereof;

FIG. 3 is a section view showing the guide means of the apparatus shown in FIGS. 1 and 2;

FIG. 4 is a section view showing the nozzle means of the apparatus shown in FIGS. 1 and 2;

FIG. 5 is a section view showing the relative disposition of a bare single element such as an electrical conductor and filler material in a rectangular groove in accordance with the present invention;

FIG. 6 is a view similar to FIG. 5 but showing the bare single conductor disposed in a dovetailed-shape groove such that the conductor is automatically held in position by groove; and

FIG. 7 is a view similar to FIG. 5 but showing an insulated double conductor electrical wire positioned within a rectangularly shaped groove.

Referring now to the drawings in detail, and specifically to FIGS. 1 and 2, there is shown a tool 10 for disposing an element of indefinite continuous length along a predetermined path, i.e., the groove 14 formed in the surface of a base member 16, which may be any structural member such as a wall, floor, etc. While a variety of such elements may be so disposed, the present description will for convenience, be directed to the disposition of an electrical conductor 12.

The tool 10 is comprised of a housing 18 which is constructed and arranged to be manually moved parallel to the surface of the base member 16 and above the groove 14 therein. To this end, the housing 18 is provided with a substantially hollow handle 20 extending in the direction of tool movement and a substantially hollow working head 22. The handle 20 is preferably shaped and constructed so that it may be readily grasped by a single hand of the operator of the tool. The working head 22 is shaped to extend from the handle 20 and depend downwardly to the base member 16.

The housing 18 is also constructed to carry a reel 24 of electrical wire 12. The reel 24 is supported by an arm 26, preferably integrally defined in the working head 22 of the housing 18; and the reel 24 is connected to the arm 26 by suitable axle and bearing means 28. As best shown in FIG. 2, the wire 12 which is carried by reel 24 is first fed from the reel to an opening 30 communicating with the interior of the working head 22, and then fed through the working head 22 to an output guide 32.

The output guide 32 projects downwardly from the working head 22 and is constructed both to receive the electrical wire 12 and to position same on the surface of the base member 16. As shown in FIGS. 2 and 3, the guide 32 has its end 34 shaped so as to curve the received wire 12 and to arrange it parallel to the base member 16 in the groove 14. As shown in FIG. 2, an additional guide 36 is provided within the housing 18 to cooperate with both the opening 30 and the guide 36. The guide 36 functions to facilitate the movement of the wire 12 through the working head 22 of housing 18 to the output guide 32.

Referring still to FIG. 2, a supply chamber 38 is provided in the working head 22 of the housing, and extends from the top portion of the working head to nozzle 4-0. The supply chamber is substantially tubular and has a top opening 42. The supply chamber 38 is constructed and arranged in the housing 18 to receive through the top opening 42 a substantially cylindrical stick 44 of thermoplastic material or the like. By way of example, the stick 44 may be comprised of any of the vinyl compounds commonly used as adhesives and fillers in the construction industry. A heating element, shown generally at 46 and defined by windings 48 of a heating conductor, is provided about the outer surface of the supply chamber 38. The heating element 46 constitutes heating means for heating the stick 44 of thermoplastic material to a pliable state. As shown in FIG. 2, the heating element 46 is connected through a switch 50 to a powerline 52 suitably connected to a source of electrical power (not shown). The switch 50 is comprised of a pair of spaced-apart electrodes 54 which maintain the switch in the open condition, but which are constructed to be pushed together to close the switch and thus complete an electrical circuit to the heating element 46.

As alluded to above, and as shown in FIGS. 2 and 4, nozzle 40 is connected to the supply chamber 38 and is constructed and arranged to apply a layer 56 of the pliable thermoplastic material contained in the supply chamber 38 over the electrical wire 12 which has been positioned on the surface of the base member 16 by the mentioned guide 32. To this end, the nozzle 40 is directly aligned with the guide 32 and is positioned to its rear with reference to the direction of tool movement.

Returning to FIG. 2, it will be noted that a baffle 58 is provided to extend perpendicularly across the lower portion of the supply chamber 38. The baffle 58 functions to regulate the passage of the thermoplastic material from the supply chamber 38 to the nozzle 40, and thus also to regulate the amount of said material deposited in the groove 14. Specifically, the baffle 58 is constructed to slide perpendicularly across the supply chamber through a slot 60 provided in the sidewall of the supply chamber 38 and is arranged to engage a recess 62 in the opposite inside wall of the supply chamber. The baffle 58 is moved by a trigger 64 which is pivotally connected to the baffle 58 at 66. The trigger 64 is in turn fixedly mounted within the housing 18 to pivot about pin 68. A leaf spring 70 is connected in the housing 18 to maintain or bias the trigger 64 in a position which permits the connected baffle 58 to engage the recess 62 and thus to close off the supply chamber 38 from the nozzle 40. The trigger 64 is provided with a cam section 72 which is constructed to engage and push together the spaced-apart electrodes 54 of the switch 50. The cam section 72 is positioned on trigger 64, however, so as to engage and close the spaced-apart electrodes 54 only when the baffle 58 is moved by the trigger to the open position.

In operation, the end portion of the electrical wire 12 wound on the reel 24 is initially fed into the housing 18 via the opening 30, then fed through the guides 36 and 32, respectively, and secured within the groove 14. Thereafter, the trigger 64 is moved by the operator of the tool to pivot about the pin 68 so that the cam section 72 thereof pushes together the spaced-apart electrodes 54 of the switch 50, thus closing switch 50 and energizing the heating element 46. The heating element 46 rapidly generates sufficient heat around and within the supply chamber 38 to heat portions of stick 44 into a pliable state. The movement of the trigger 64 simultaneously withdraws the baffle 58 from the recess 62 and moves it to a position allowing substantial communication between the supply chamber 38 and the nozzle 40. When the baffle 58 is thus positioned, the pliable thermoplastic material contained in the supply chamber flows down through the remaining portion of the supply chamber 38, through the nozzle 40 and forms the covering layer 56 in the groove 14. Thus, it will be seen that as the tool is slowly moved along the surface of the base member 16 and directly above the groove 14, the electrical wire 12 is selectively unwound from the reel 24 and positioned within the groove 14 by the guide 32 and secured therein by the layer 56 of thermoplastic material provided by the nozzle 40.

As shown in FIG. 5, the layer 56 of thermoplastic material provided by the nozzle 40 is preferably applied in sufficient volume so as to completely fill the groove 14 and provide a flush and smooth surface relative to the remaining surface of the base member 16. The smooth surface may be achieved by providing a grading tool on the nozzle 40, or as a separate step by using any known hand grading tool. Also, as shown in FIGS. 5 and 7, the above-described tool 10 may readily be used to dispose elongated elements of many configurations and constructions. As shown in FIG. 5, the tool 10 may be used to dispose an uninsulated single conductor wire 74, or as shown in FIG. 7, the tool may be used to dispose an insulated double conductor electric wire 76. In the former instance, great economy is realized since the thermoplastic material deposited thereon acts as an insulator for the wire, and thus no other insulation is necessary. Also as shown in FIG. 6, in order to form a better base for the layer 56 of filler or thermoplastic material and in order to better hold the electric wire 78 the groove 14 may be dovetailed.

Thus, it will be appreciated from above that the present invention provides a method and tool for installing wiring systems and the like which are not only simple and may be carried out and operated by any handyman of ordinary skill, but also are economical to make and use.

Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious to those skilled in the art to which the invention pertains, after understanding the invention, that various changes and modifications may be made therein without departing from the spirit and scope of the invention, as defined by the claims appended hereto.

What is claimed as new and desired to be secured by Letters Patent is:

1. Apparatus for disposing an element of indefinite continuous length along a predetermined path on the surface of a base member comprising a housing, said housing being constructed to carry a predetermined length of said element and arranged to be moved along said predetermined path, guide means projecting from said housing and constructed to receive said element carried by said housing and to position same on the surface of said base member, supply chamber means arranged in said housing and constructed to contain material for securing said element to the surface of said base member, and nozzle means connected to said supply chamber means and also projecting from said housing, said nozzle means being arranged to apply said material over said element positioned on said surface whereby said wire is secured to said base member as said apparatus is moved along said predetermined path, said apparatus being of a size that can be held in the operator's hand during operation.

2. Apparatus for disposing an element of indefinite continuous length as in claim I wherein said guide means and said nozzle means project from said housing in aligned relationship with regard to said predetermined path.

3. Apparatus for disposing an element of indefinite continuous length as in claim 1 further including means connected in said housing for regulating the passage of said material from said supply chamber means to said nozzle means.

4. Apparatus for disposing an element of indefinite continuous length as in claim 1 wherein said supply chamber means is constructed to contain thermoplastic material and further including heating means cooperating with said supply chamber means for heating said thermoplastic material to a pliable state.

5. Apparatus for disposing an element of indefinite continuous length as in claim 4 further including regulating means cooperating with said supply chamber means and said nozzle means for regulating the passage of said material from said supply chamber to said nozzle means and trigger means projecting from said housing and connected to said regulating means, said trigger means being constructed to be manually moved to actuate said regulating means.

lOlO'll 041R 6. Apparatus for disposing an element of indefinite continuous length as in claim 5 further including switch means connected to said heating means and constructed to selectively actuate same, said trigger means also being constructed to open and close said switch means.

7. Apparatus for disposing an element of indefinite continuous length as in claim ll wherein said housing is constructed to carry said element on a reel and wherein said guide means is arranged to receive and end of the element on said reel and position same on said surface of said base member whereby as said apparatus is moved along said predetermined path said element is selectively unwound from said reel and secured to said base member by said material.

8. Apparatus for disposing electrical wire within a longitudinally extending groove provided in the surface of a base member comprising a housing, said housing being constructed to carry a predetermined length of said electrical wire and arranged to be moved parallel above said groove, guide means arranged to receive said electrical wire carried by said housing and constructed to project into said groove and position said electrical wire therealong, supply chamber means arranged in said housing and constructed to contain filler material for holding said electrical wire in said groove, nozzle means connected to said supply chamber means and constructed to apply said filler material over said electrical wire positioned in said groove by said guide means whereby said electrical wire is enclosed within said groove as said apparatus is moved parallel above said groove, said apparatus being of a size that can be held in the operators hand during operation.

9. Apparatus for disposing electrical wire as in claim 8 wherein said guide means and said nozzle means are constructed to project from said housing and simultaneously cooperate with said groove.

10. Apparatus for disposing electrical wire as in claim 8 wherein said supply chamber means is constructed to contain thermoplastic filler material and further including means for heating said thermoplastic filler material to a pliable state.

11. Apparatus for disposing electrical wire as in claim 10 further including regulating means cooperating with said supply chamber means and said nozzle means for regulating the passage of said thermoplastic material from said supply chamber to said nozzle means and trigger means projecting from said housing and connected'to said regulating means,

said trigger means being constructed to be manually moved to actuate said regulating means.

12. Apparatus for disposing electrical wire as in claim ll further including switch means connected to said heating means and constructed to selectively actuate same, said trigger means also being constructed to open and close said switch means.

13. Apparatus for disposing electrical wire as in claim 8 wherein said housing is constructed to carry said electrical wire on a reel and wherein said guide means is arranged to receive an end of the electrical wire on said reel and position same within groove whereby as said apparatus is moved parallel to said groove said electrical wire is selectively unwound from said reel and secured to said base member within said groove.

14. Apparatus for disposing electrical wire along a predetermined path on the surface of a base member comprising a housing, said housing being constructed to carry a reel containing windings of said electrical wire and arranged to be moved along said predetermined path, guide means projecting from said housing and constructed to receive said electrical wire carried by said housing and to position same on the surface of said base member, supply chamber means arranged in said housing and constructed to receive substantially solid thermoplastic material for securing said electrical wire to the surface of said base material, heating means connected to said supply chamber means and constructed to heat said thermoplastic material to a pliable state, nozzle means communicating with said supply chamber means and also projecting from said housing, said nozzle means being arranged to apply said thermoplastic material in the pliable state over said electrical wire positioned on said surface, regulating means connected to said supply chamber means for regulating the passage of said thermoplastic material from said supply chamber to said nozzle means, switch means connected to said heating means and adapted to energize same, and trigger means projecting from said housing and connected both to said regulating means and said switch means, said trigger means being constructed to be moved to simultaneously actuate said switch means and said regulating means whereby as said apparatus is moved along said predetermined path said electrical wire is selectively unwound from said reel and secured to said base member by said thermoplastic material. 

1. Apparatus for disposing an eleMent of indefinite continuous length along a predetermined path on the surface of a base member comprising a housing, said housing being constructed to carry a predetermined length of said element and arranged to be moved along said predetermined path, guide means projecting from said housing and constructed to receive said element carried by said housing and to position same on the surface of said base member, supply chamber means arranged in said housing and constructed to contain material for securing said element to the surface of said base member, and nozzle means connected to said supply chamber means and also projecting from said housing, said nozzle means being arranged to apply said material over said element positioned on said surface whereby said wire is secured to said base member as said apparatus is moved along said predetermined path, said apparatus being of a size that can be held in the operator''s hand during operation.
 2. Apparatus for disposing an element of indefinite continuous length as in claim 1 wherein said guide means and said nozzle means project from said housing in aligned relationship with regard to said predetermined path.
 3. Apparatus for disposing an element of indefinite continuous length as in claim 1 further including means connected in said housing for regulating the passage of said material from said supply chamber means to said nozzle means.
 4. Apparatus for disposing an element of indefinite continuous length as in claim 1 wherein said supply chamber means is constructed to contain thermoplastic material and further including heating means cooperating with said supply chamber means for heating said thermoplastic material to a pliable state.
 5. Apparatus for disposing an element of indefinite continuous length as in claim 4 further including regulating means cooperating with said supply chamber means and said nozzle means for regulating the passage of said material from said supply chamber to said nozzle means and trigger means projecting from said housing and connected to said regulating means, said trigger means being constructed to be manually moved to actuate said regulating means.
 6. Apparatus for disposing an element of indefinite continuous length as in claim 5 further including switch means connected to said heating means and constructed to selectively actuate same, said trigger means also being constructed to open and close said switch means.
 7. Apparatus for disposing an element of indefinite continuous length as in claim 1 wherein said housing is constructed to carry said element on a reel and wherein said guide means is arranged to receive and end of the element on said reel and position same on said surface of said base member whereby as said apparatus is moved along said predetermined path said element is selectively unwound from said reel and secured to said base member by said material.
 8. Apparatus for disposing electrical wire within a longitudinally extending groove provided in the surface of a base member comprising a housing, said housing being constructed to carry a predetermined length of said electrical wire and arranged to be moved parallel above said groove, guide means arranged to receive said electrical wire carried by said housing and constructed to project into said groove and position said electrical wire therealong, supply chamber means arranged in said housing and constructed to contain filler material for holding said electrical wire in said groove, nozzle means connected to said supply chamber means and constructed to apply said filler material over said electrical wire positioned in said groove by said guide means whereby said electrical wire is enclosed within said groove as said apparatus is moved parallel above said groove, said apparatus being of a size that can be held in the operator''s hand during operation.
 9. Apparatus for disposing electrical wire as in claim 8 wherein said guide means and said nozzle means are constructed to project from said housing and simultaneOusly cooperate with said groove.
 10. Apparatus for disposing electrical wire as in claim 8 wherein said supply chamber means is constructed to contain thermoplastic filler material and further including means for heating said thermoplastic filler material to a pliable state.
 11. Apparatus for disposing electrical wire as in claim 10 further including regulating means cooperating with said supply chamber means and said nozzle means for regulating the passage of said thermoplastic material from said supply chamber to said nozzle means and trigger means projecting from said housing and connected to said regulating means, said trigger means being constructed to be manually moved to actuate said regulating means.
 12. Apparatus for disposing electrical wire as in claim 11 further including switch means connected to said heating means and constructed to selectively actuate same, said trigger means also being constructed to open and close said switch means.
 13. Apparatus for disposing electrical wire as in claim 8 wherein said housing is constructed to carry said electrical wire on a reel and wherein said guide means is arranged to receive an end of the electrical wire on said reel and position same within groove whereby as said apparatus is moved parallel to said groove said electrical wire is selectively unwound from said reel and secured to said base member within said groove.
 14. Apparatus for disposing electrical wire along a predetermined path on the surface of a base member comprising a housing, said housing being constructed to carry a reel containing windings of said electrical wire and arranged to be moved along said predetermined path, guide means projecting from said housing and constructed to receive said electrical wire carried by said housing and to position same on the surface of said base member, supply chamber means arranged in said housing and constructed to receive substantially solid thermoplastic material for securing said electrical wire to the surface of said base material, heating means connected to said supply chamber means and constructed to heat said thermoplastic material to a pliable state, nozzle means communicating with said supply chamber means and also projecting from said housing, said nozzle means being arranged to apply said thermoplastic material in the pliable state over said electrical wire positioned on said surface, regulating means connected to said supply chamber means for regulating the passage of said thermoplastic material from said supply chamber to said nozzle means, switch means connected to said heating means and adapted to energize same, and trigger means projecting from said housing and connected both to said regulating means and said switch means, said trigger means being constructed to be moved to simultaneously actuate said switch means and said regulating means whereby as said apparatus is moved along said predetermined path said electrical wire is selectively unwound from said reel and secured to said base member by said thermoplastic material. 